Waterborne soft-feeling coating composition with high gloss

ABSTRACT

A waterborne, soft feeling coating composition and a substrate coated with the composition. The coating composition comprises an aqueous solvent, a resin, and an alcohol alkoxylate surfactant. The invention is also directed to a process of making the waterborne coating composition of the invention, and a process of coating a substrate with the waterborne coating composition.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of U.S. patent application Ser. No.10/099,036 filed Mar. 15, 2002 now U.S. Pat. No. 6,750,276, which is aDivisional of U.S. patent application Ser. No. 08/692,138 filed Aug. 5,1996 now abandoned, the disclosures of which are incorporated byreference in their entireties.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to soft-feeling coatings, and more particularlyto waterborne soft-feeling coatings that contain surfactants and resultin a lacquer-like finish with high gloss.

2. Brief Description of the Related Art

Soft-feeling paints and coatings provide desirable aesthetic and tactilecharacteristics for a variety of applications, particularly articlesthat are touched by consumers. Automotive manufacturers have usedsoft-feeling coatings on instrument panels, armrests, and horn buttonsto give hard, glossy plastic components a velvety smooth matte finish.Other consumer products, such as notebook computers and cellular phones,also use soft-feeling coatings to enhance look and finish of theproducts and give the appearance of a high-quality product.

Typical soft-feeling coating compositions use a two-component (2K)solvent based paint. While this two-component coating has desirablefeatures, the content of volatile organic compounds (VOCs) is high, onthe order of 4.2 to 5.0 pounds per gallon. Increasingly stringentenvironmental regulations have forced coating manufacturers to use othersolvent systems with lower levels of VOCs. In addition, two-componentsoft coatings often result in different gloss levels due to varyingambient humidity and different rates of solvent evaporation on differentareas of the coated article. Due to these problems, some manufacturershave experienced difficulties in producing uniformly finished parts.

One component (1K) waterborne soft-feel coatings have been developed asan alternative to solvent-based coatings. These coatings haveconsiderably less VOCs (on the order of 1.5 to 2 pounds per gallon).However, they are generally regarded as not as “soft” as thetwo-component solvent-based coatings. In addition, one componentwaterborne coatings exhibit poor chemical resistance and weatherability.

Recently, two-component waterborne soft-feel coating systems have beendeveloped to overcome the shortcomings of the one-component system. Atwo-component waterborne system is described in a technical journalarticle by Ahmed (SAE Spec. Pub. SP-1135, pp 59-64 (1996)), and byHegedus et al., J. Coat. Tech. 68, 51-61 (January 1996). However, suchtwo component waterborne systems provide about one-half the level ofgloss (measured as “distinction of image” or DOI) provided by the twocomponent solvent-based system. Accordingly, such waterborne coatingsare not suitable when a high gloss, soft feeling coating is desired. Inaddition, these coatings display inadequate wetting and flowcharacteristics when applied to substrates, which, in turn, result insurface defects. To combat these defects, additives such as flowmodifiers are included to enhance the flow and level attributes of thecomposition.

Flow modifiers perform many functions in applied coatings such as paint.Flow modifiers are used primarily to reduce or eliminate surfacedefects, such as craters, fisheyes, pinholes, and orange peel. They alsoaid in pigment dispersion, help facilitate air release, improvesubstrate wetting, and promote flow and leveling. Although flowmodifiers are typically used at 0.25-0.5% by weight in liquid coatingsand at 0.5-1.5% by weight in powder coatings, based upon the weight ofthe coating, they can be effective at levels as low as in the parts permillion (ppm) range.

Surfactant compositions have been disclosed for purposes such ascleaning compositions and rinse aids. For example, U.S. Pat. No.4,989,621 to Pruehs et al. discloses the use of hydroxyalkylpolyethylene glycol ethers in rinse aid compositions for dishwashingmachines. However, to the knowledge of the present inventors, suchsurfactants have not been disclosed for coating applications.

U.S. Pat. No. 4,925,587 to Schenker et al. discloses hydroxyalkylpolyethylene glycol and hydroxyalkyl polypropylene glycol ethers as foaminhibiting additives in low foam cleaning preparations. However, to theknowledge of the present inventors, such additives have not beendisclosed for coating compositions.

U.S. Pat. No. 3,956,401 to Scardera et al. disclose low foaming,biodegradable nonionic surfactants of the formulaRO—(CH₂—CHR′—O)_(x)—(CH₂—CH₂—O)_(y)—(CH₂—CHR″—O)_(z)

-   -   where R is a linear alkyl hydrocarbon having an average from        about 7 to 10 carbon atoms, R′ is a linear alkyl hydrocarbon of        about 1 to 4 carbon atoms, R″ is a linear alkyl hydrocarbon of        about 1 to about 4 carbon atoms, x is an integer from 1 to 6, y        is an integer from 4 to 15, and z is an integer from 4 to 25.        Such surfactants are liquid at room temperature, nongelling in        aqueous solutions, and are useful as detergents. However, such        surfactants have not been heretofore disclosed for coating        compositions to the knowledge of the inventors.

Amphoteric surfactants have been disclosed as a component of coatingcompositions. U.S. Pat. No. 5,399,617 to Farwaha et al. disclosesamphoteric surfactants which are suitable as wet adhesion promoters andfreeze-thaw stabilizers for use in both all acrylic and vinyl acrylicthermoplastic latex paints. However, the amphoteric nature of thesurfactants makes them incompatible with certain solvents andundesirable for noncharged or positively charged surfaces.

Accordingly, there is still a need in the art for a waterborne,two-component coating composition that includes a surfactant to provideimproved flow characteristics, soft-feel, and high gloss, as well asmeet strict environmental guidelines. The present composition meets thatneed.

SUMMARY OF THE INVENTION

The present invention is a waterborne, two-component coating compositionthat includes an alcohol alkoxylate surfactant. The composition of theinvention provides improved flow characteristics during application to asubstrate. When applied to a substrate, the coating composition displaysenhanced gloss and soft feel after drying.

One aspect of the present invention is directed to a waterborne coatingcomposition, comprising:

-   -   (A) an aqueous solvent;    -   (B) a resin; and    -   (C) a surfactant, said surfactant having a formula selected from        the group consisting of:        R₁O—(CH₂—CH(R₂)—O)_(p)—(CH₂—CH₂—O)_(y)—R₃  (i)    -   where R₁ is H or a substituted or unsubstituted alkyl group        having 6-10 carbon atoms; R₂ is a substituted or unsubstituted        alkyl group having 1-4 carbon atoms; R₃ is selected from the        group consisting of —(CH₂—CH(R₂)—O)_(x)—H, —H, and        —CH₂—CH(OH)—(CH₂)_(z)CH₃; p is an integer from 0-6; x is an        integer from 1-6; y is an integer from 4-35; and z is an integer        from 1-14; and        H—(O—CHR—CH₂)_(a)—(O—CH₂—CHR)_(b)—(O—CH₂—CHR)_(a)—OH  (ii)    -   where R is H or CH₃; a is an integer from about 1 to about 35;        and b is an integer from about 5 to about 75.

Another aspect of the invention is directed to a coated substrate,comprising a substrate and a dry coating on the substrate, the drycoating comprising

-   -   (A) a resin; and    -   (B) a surfactant;        -   said surfactant having a formula selected from the group            consisting of:            R₁O—(CH₂—CH(R₂)—O)_(p)—(CH₂—CH₂—O)_(y)—R₃  (i)    -   where R₁ is —H or a substituted or unsubstituted alkyl group        having 6-10 carbon atoms; R₂ is a substituted or unsubstituted        alkyl group having 1-4 carbon atoms; R₃ is selected from the        group consisting of —(CH₂—CH(R₂)—O)_(x)—H, —H, and        —CH₂—CH(OH)—(CH₂)_(z)CH₃; p is an integer from 0-6; x is an        integer from 1-6; y is an integer from 4-35; and z is an integer        from 1-14; and        H—(O—CHR—CH₂)_(a)—(O—CH₂—CHR)_(b)—(O—CH₂—CHR)_(a)—OH  (ii)    -   where R is H or CH₃; a is an integer from about 1 to about 35;        and b is an integer from about 5 to about 75.

Another aspect of the invention is directed to a process of making awaterborne coating composition, comprising combining an aqueous solvent,a resin, and a surfactant, said surfactant having a formula selectedfrom the group consisting of:R₁O—(CH₂—CH(R₂)—O)_(p)—(CH₂—CH₂—O)_(y)—R₃  (a)

-   -   where R₁ is —H or a substituted or unsubstituted alkyl group        having 6-10 carbon atoms; R₂ is a substituted or unsubstituted        alkyl group having 1-4 carbon atoms; R₃ is selected from the        group consisting of —(CH₂—CH(R₂)—O)_(z)—H, —H, and        —CH₂—CH(OH)—(CH₂)_(z)CH₃; p is an integer from 0-6; x is an        integer from 1-6; y is an integer from 4-35; and z is an integer        from 1-14; and        H—(O—CHR—CH₂)_(a)—(O—CH₂—CHR)_(b)—(O—CH₂—CHR)_(a)—OH  (b)    -   where R is H or CH₃; a is an integer from about 1 to about 35;        and b is an integer from about 5 to about 75; the combination        forming a waterborne coating composition.

Another aspect of the invention is directed to a process of coating asubstrate, comprising applying a waterborne coating composition to asubstrate, the waterborne coating composition comprising aqueoussolvent, a resin, and a surfactant, said surfactant having the formulaselected from the group consisting of:R₁O—(CH₂—CH(R₂)—O)_(p)—(CH₂—CH₂—O)_(y)—R₃  (a)

-   -   where R₁ is —H or an a substituted or unsubstituted alkyl group        having 6-10 carbon atoms; R₂ is a substituted or unsubstituted        alkyl group having 1-4 carbon atoms; R₃ is selected from the        group consisting of —(CH₂—CH(R₂)—O)_(z)—H, —H, and        —CH₂—CH(OH)—(CH₂)_(z)CH₃; p is an integer from 0-6; x is an        integer from 1-6; y is an integer from 4-35; and z is an integer        from 1-14; and        H—(O—CHR—CH₂)_(a)—(O—CH₂—CHR)_(b)—(O—CH₂—CHR)_(a)—OH  (b)    -   where R is —H or CH₃; a is an integer from about 1 to about 35;        and b is an integer from about 5 to about 75.

These and other aspects will become apparent upon reading the followingdetailed description of the invention.

DETAILED DESCRIPTION OF THE INVENTION

It has been surprisingly found that an alcohol alkoxylate surfactantadded to a waterborne coating composition provides improved flowcharacteristics during application of the composition to a substrate. Inaddition, the alcohol alkoxylate surfactant aids in leveling thecomposition on the substrate as it is applied, and results in enhancedgloss and soft feel when the composition is dry.

As used herein, the term “soft feel” refers to a coating with avelvety-smooth texture when touched. The term “surfactant” is usedherein to refer to any compound that reduces surface tension whendissolved in water or water solutions, or which reduces interfacialtension between two liquids, or between a liquid and a solid. The term“lacquer-like” refers to finishes with Specular Gloss levels of 75 andhigher.

Solvents useful in the waterborne composition of the invention includeany aqueous solvent that is capable of blending the ingredients of theformulation and not separating into distinct phases over time. Onepreferred solvent is water, because it functions as both as a solventand a carrier of the other water soluble components of the formulation.In addition, various water soluble organic solvents known in the paintart may be added to the water solvent. Useful water-soluble organicsolvents include, but are not limited to, N-methylpyrrolidone (NMP) forhydroxy-functional acrylic-polyurethane resin binders, and propyleneglycol for acrylic resin binders. These water soluble organic solventsare added to the water solvent to form water/N-methypyrrolidone mixturesand water/propylene glycol mixtures which are effective solvents for theformulation. In some applications, resins are available as aqueousemulsions and additional solvents are not required. One example of suchan emulsified resin is “CARBOSET” CR-714 acrylic emulsion, whichincludes acrylic polymers emulsified in aqueous solvents. Preferably,the total solvent content of the formulation is from about 20 to about80% by weight of the total composition.

The resin component of the composition may be any conventional bindingresin known in the coating and paint arts, such as polyurethane,acrylic, epoxy, polyester, vinyl, latex, styrene acrylic,hydroxyl-functional acrylic-polyurethane, alkyd, and combinations ofthese. The resin component of the composition is preferably present insufficient quantity to cause adhesion of the fillers or pigments to thesubstrate, and to hold and/or bind all the other materials of thecomposition together. Preferably, the binder component makes up fromabout 12 to about 85% by weight of the final composition.

The composition of the present invention includes a surfactant componentof the general formula:R₁O—(CH₂—CH(R₂)—O)_(p)—(CH₂—CH₂—O)_(y)—R₃

-   -   where R₁ is —H or a substituted or unsubstituted alkyl group        having 6-10 carbon atoms; R₂ is a substituted or unsubstituted        alkyl group having 1-4 carbon atoms, R₃ is        —(CH₂—CH(R₂)—O)_(x)—H; or —H; or —CH₂—CH(OH)—(CH₂)_(z)CH₃); p is        an integer from 0-6; x is an integer from 1-6; y is an integer        from 4-35; and z is an integer from 1-14. The surfactant        included in the present composition acts as a homogenizing agent        for the binder and the other components of the composition. The        nonpolar nature of the surfactant homogenizes the components        into a coating composition that flows smoothly and evenly, and        leaves substantially no imperfections on the substrate. In        addition, surfactant component of the invention acts as a        defoaming agent to remove air from the mixed coating blend,        which improves flow and enhances the final coating. The amount        of surfactant included in the composition of the invention        preferably ranges from 0.01 to 3.0% by weight of the total        composition, and more preferably between 0.2-0.5% by weight of        the total composition.

Exemplary surfactants useful in the composition of the present inventioninclude poly(oxyethylene/oxypropylene)alkyl ethers sold under thetrademark “POLYTERGENT”. If desired, this compound is suitablyend-capped with a lower alkyl group, such as propylene oxide (PO), soldunder the trade name “POLY-TERGENT” SLF Series. End-capped compounds areparticularly useful because they discourage foaming during preparationof the formulation. A particularly useful surfactant ispoly(oxyethylene/polypropylene)monohexyl ether, monooctyl ether, andmonodecyl ether sold under the tradename of “POLYTERGENT S405LF”.

Other useful surfactants includes alkene oxide-capped linear alcoholalkoxylates containing ethylene oxide moieties in the backbone andcontain at least one propylene oxide moiety in the backbone, and soldunder the trade name “POLY-TERGENT” SLF-18B Series. This family ofsurfactants is characterized by enhanced biodegradability. Suchsurfactants are disclosed in U.S. Pat. Nos. 4,925,587 and 4,898,621, andthe whole of each is incorporated by reference herein in their entirety.Advantageously, use of the “POLY-TERGENT” SLF Series and/or“POLY-TERGENT” SLF-18B Series surfactants in the present inventionavoids the need for an antifoaming agent in the formulations and workingcompositions of the present invention.

Alternatively, nonionic surfactants which are coblock polymers ofethylene oxide/propylene oxide monomers may be used in the formulationof the invention. These compounds are known commercially as the“POLY-TERGENT” P and E Series and are available from Olin corporation.These compounds have the general formulaH—(O—CHR—CH₂)_(a)—(O—CH₂—CHR)_(b)—(O—CH₂—CHR)_(a)—OH

-   -   where R is —H or CH₃; a is an integer from about 1 to about 35;        and b is an integer from about 5 to about 75 may be used.

One preferred surfactant has the formulaH—(OCH₂CH₂)_(x)—(OCH₂CHCH₃)_(y)—(OCH₂CH₂)_(x)—OH

-   -   where x is an integer from 1 to 35, and y is an integer from 10        to 75. Several preferred compositions of this surfactant are        described in Table I which illustrates various useful        combinations of x and y groups as used in the above formula.        Values of x that are not whole numbers represent the average        value of x derived from a population of molecules. “A” denotes a        surfactant preparation that is approximately 10% EO capped, “B”        is a surfactant preparation that is approximately 20% EO capped,        “C” is a surfactant preparation that is approximately 30% EO        capped, etc. The first two digits of each name represents the        approximate total molecular weight of the PO groups divided        by 100. Each compound listed in Table I is available        commercially under the trademark “POLY-TERGENT”.

TABLE I Cmpd Name x y % EO P-9E 11.5 16 51 P-17A 2.5 31 11 P-17B 7.5 3127 P-17D 12 31 36.5 P-22A 4 39 13.5 P-22E 26 40 50 P-32A 4.5 60 10 P-32C14.5 52 30 P-32D 17 56 31.7 P-32E 33.5 51 50 P-37C 18.5 71 28

Another preferred surfactant has the formula:H—(OCH(CH₃)CH₂)_(Y)—(OCH₂CH₂)_(X)—(OCH₂CH(CH₃))_(Y)—OH

-   -   where x is an integer from 5 to 20 and y is an integer from 15        to 25. Several preferred compositions are described in Table II        which illustrate various useful combinations of x and y groups        as used in the above formula. In Table II, “A” denotes a        surfactant that is approximately 10% PO capped, and “B” denotes        a surfactant that is approximately 20% PO capped. The first two        digits of each name represents the approximate total molecular        weight of the EO groups divided by 100. Each compound listed in        Table II is available commercially under the trademark        “POLY-TERGENT”.

TABLE II Cmpd Name x y % PO E-17A 7 19 88 E-17B 15 17 75 E-25B 16 23 79

The composition of the invention may also include additional additives,such as fillers, pigments, dispersing agents, antifoaming agents,antimicrobial agents, and combinations thereof. Generally, thesecomponents are included to add certain characteristics to thecomposition of the invention.

Fillers may be added to the composition of the invention to fill holesand other surface imperfections in the substrate. The filler componentincluded in the composition is preferably a solid, particulate materialof colloidal size or greater. Filler materials useful in the compositionof the invention include fillers known in the art, such as common clays,kaolin, montmorillonite (bentonite), clay mica (muscovite), andchlorite, or fine-grained hydrous aluminosilicates which frequentlycontain appreciable amounts of iron, magnesium, calcium, sodium andpotassium. Alternatively, other fillers known in the art, such ascalcium carbonate, may be implemented. Preferably, the filler comprisesfrom about 0% to about 30% by weight of the total weight of thecomposition, and more preferably about 10% to about 25% by weight of thetotal composition.

The formulation of the invention may be made without pigments to producea clearcoat for application to previously colored substrates, such asstained wood, painted automobile body parts, automobile interior parts,automobile airbags, and the like. However, pigments may be added to givethe final composition any desirable hue. For example, white pigmentssuch as titanium dioxide, talc, or zinc oxide render the final coatingwhite. Alternatively, other pigments known in the art may be added togive the formulation any color, such as red, orange, yellow, green,blue, indigo, violet, or combinations of these. Useful pigments include“TINTS-ALL 11” lamp black, “TINTS-ALL 29” prussian blue (phthalo blue),“TINTS-ALL 15” American vermillion, “TINTS-ALL 1” yellow light, or otherpigment known in the paint and coating art. Preferably, the pigmentcomprises from about 0% to about 50% of the total weight of thecomposition.

The dispersing agent may be a material such as nonionic surfactants andacrylic polymers, such as 2,5-furandione polymer sold under thetradename “TAMOL 731”. The dispersing agent is generally added in smallpercentages to help disperse the fillers and smooth the coating onto thesubstrate. Preferably, the dispersing agents comprise 0.01 to 5% of thefinal coating weight.

The antifoaming agent may be silicon oils, mineral oils, modifiedalcohol ethoxylates, EO/PO block copolymers (repeating blocks of ethyoxyand propoxy groups), phosphate esters, hydrophobicsilica, and fattyalcohols as well as blends of these defoamers. Other antifoaming agentsand/or leveling agents include coblock polymers of EO/PO sold under thetrademark “BASF PLURONICS”, alkoxylated straight chain alcohols soldunder the trademark “PLURFACS”; alkoxylated fatty acids, alcohols, orglycols sold under the trademark “ANTAROX”; alkoxylated alcohols andcoblock polymers of EO/PO sold under the trademark “MACOL”; alkylphenolalkoxylates sold under the trademark “TRITON CF”; alkoxylated alcoholssold under the trademark “TRITON DF”; alkylated secondary alcohols soldunder the tradename “TERGITOL”, “MINIFOAM”, “15S” and “TMN”; andalkoxylated linear alcohols and glycols sold under the trademark“SURFONIC”. The antifoaming agent preferably comprises about 0 to about5% by weight of the final coating weight.

An antimicrobial agent may also be included in the composition of theinvention. Antimicrobial compounds discourage growth of mold and funguswhen the formulation of the invention is applied to damp areas, such asstructural exteriors in damp environments, boats, or other areas wheregrowth of mold and fungus are common. Compounds useful as antimicrobialagents include zinc pyrithione, sodium pyrithione,2,2′-dithiobis(pyridine-1-oxide), 10,10′-oxybisphenoxarsine;N-(trichloromethylthio)-4-cyclo-hexene-1,2-dicarbonamide;2,3,5,6-tetrachloro-4-(methlysulfonyl)pyridine; N-(trichloromethylthio)phthalimide; N-hydroxy-6-octyloxypyridine-2(1H) 1, ethanolamine salt;dodecylbis(hydroxyethyl)dioctyl ammonium phosphate anddodecylbis(hydroxyethyl) octyl hydrogen ammonium phosphate and otherphosphate amines; 3-trimethyoxysilylpropyl dimethyloctadecylammoniumchloride and other quaternary ammonia compounds including quaternaryammonium salts; 2,4,4′-trichloro-2′-hydroxy-diphenylether and otherphenol derivatives such as 2 phenylphenol or dichlorophene or2,2′-methylenebis(4-chlorophenol); diodomethyl-p-tolyl sulfone,2-n-octyl-4-isothiazolin-3-one and other isothiazoline derivatives suchas benzisothiazoline and their combinations; organometallics such astributyltin compounds: tributyltinoxide or tributyltin maleate;dithio-2,2′-bis(benzmethylamide);N-trichloromethylthio-4-cyclohexene-1,2-dicarboximide;2-(4-thiazolyl)benzimidazole; thiocyanic acid;2-benzothiazolylthio)methyl ester; 2,4,5,6,tetrachloro-1,3-benzenedicarbonitrile;2[(trichloromethyl)thio]-1H-isoindole-1,3(2H)-dione;3a,4,7,7a-tetrahydro-2[(trichloromethyl)thio]-1H-isoindole-1,3(2H)-dione;1,1-dichloro-N-methanesulfamide; alkoxysiloxane quaternary compounds;copper-8-quinolinolate; copper napthenate, copper-2-ethylhexoate;parabens, 3-iodopropargyl-N-butylcarbamate (IPBC) and sulfur compounds.Preferably, the antimicrobial component is present from about 0 to about20% by weight of the final coating formulation, and more preferably fromabout 3% to about 5% by weight of the final coating formulation.

The components of the invention may be combined using a ball mill, highintensity mixer, blender, roll mill, or other mixing device known in theart. A fraction of the solvent (about 40% to 50% of the total amount ofsolvent) is first added to the mixer or mill. Solid components, such assurfactants, pigments, and dispersing or leveling agents are added tothe solvent and mixed. Resin is then added to the mixture, followed bythe remaining solvent. All the ingredients are mixed until the desiredviscosity is produced.

The waterborne, soft-feeling coating composition of the invention may beapplied to any suitable substrate, such as wood, plastic, metal, paper,composites, plaster, or glass. When used as a clearcoat (i.e., withoutpigment), the formulation may be applied on top of a paint layer. Suchan application is useful in automobile body and interior parts, and as aprotective coating for floors subjected to heavy traffic.

The resulting coating may be applied by brushing, spraying, or rolling,and dries to a smooth coating, free of cracks, brushmarks, rollerstriations, orange peel, sagging, running, curtaining or uneven filmthickness.

The waterborne coating of the invention provides a substrate with adurable, high gloss finish (high DOI) with a soft-feeling texture. Theperformance characteristics of the coating may be evaluated by applyinga quantity of the formulation to a black and white card and spreadevenly with a draw bar to form a layer of material approximately 3 milthick. This layer is dried, and the hardness and gloss are evaluated bystandard ASTM tests described below. Drying conditions are usually attemperatures ranging from 40° F. to 400° F. and atmospheric pressure,depending on the coating composition. For example, coatings used onautomobile bodies may be dried at 300-350° F. in an oven. Coatings usedon architectural parts, such as floors and walls are generally dried at40° F. to 90° F. Preferably, drying occurs at room temperature andatmospheric pressure. The applied coating material is generally dry tothe touch in less than 24 hours. The composition is completely cured inless than 15 days.

The waterborne, soft-feeling coating composition of the invention issuitable for any substrate that requires a high-gloss, durable finishwith a soft-feel and resistance characteristics. Applications of thewaterborne, soft-feeling coating of the invention include architecturalapplications (i.e., structural walls, doors), floors, countertops,bowling balls, and the like. Floors, particularly dance floors,gymnasium floors, and basketball courts, are suitable for the coating ofthe invention because these substrates frequently require finishes thathave high gloss, yet need resistance to prevent slippage.

The following examples illustrate the composition of the invention, butare not intended to limit the scope of the invention. All parts andpercentages are by weight and all temperature are by degrees Celsius,unless explicitly stated otherwise.

Example 1

A waterborne 2-component (2K) top coat for industrial application basedon a water soluble hydroxy-functional acrylic-polyurethane was preparedas follows:

Parts by wt Component Part A 25 water (solvent) 1 N-methylpyrrolidone(solvent) 9 diacetone alcohol (solubilizer) 15 Titanium Dioxide(pigment) 7 Calcium Carbonate (filler) 2 Talc (pigment) Part B 25 water0.02 Dabco T1402 (dibutyltin antimicrobial) 0.28 POLYTERGENT S405LF(surfactant) 70.27 ACPU-1 (Hydroxyl- functional acrylic- polyurethaneresin) 10.23 PM acetate (propylene glycol methyl ether acetatesolubilizer)

The “POLY-TERGENT” S405LF surfactant is a linear alcohol alkoxylateknown chemically as poly(oxyethylene/oxypropylene)monohexyl ether,monooctyl ether, or monodecyl ether.

The ingredients of Part A were blended with a premier Caframo highintensity mixer at 5000 rpm for 20 minutes. The ingredients of Part Bwere blended separately with the mixer at 1500 rpm for 15 minutes. PartB was added to Part A and mixed at 1500 rpm for 20 minutes to totallyhomogenize the mixture.

Following homogenization, 19.20 parts by weight polyisocyanate was addedat rate of 4% per minute while the mixture is blended at 2000 rpm. Thedispersion was mixed for 45 minutes until smooth and homogenized. Thecomposition was applied to a black and white cardboard card, drawn toabout 3 mil in thickness, and dried at room temperature and pressure.

The hardness of the dried material was evaluated by the ASTM D3360Standard test method for film hardness. This test yields 8H-9H hardnessas shown on the scale below:

-   -   6B-5B-4B-3B-2B-B-HB-F-H-2H-3H-4H-5H-6H-7H-8H-9H    -   soft→hard

The gloss level of the dried material was evaluated by the ASTM D 523-89Standard test method for Specular Gloss at Gloss 60°. This test yieldsan 89.9 reading with high gloss finishes with a hard surface and softfeel.

Example 2

A waterborne 2K top coat for industrial application based on watersoluble hydroxy-functional acrylic-polyurethane without filler was madeas follows:

Parts by wt Component Part A 50 water 1 N-methylpyrrolidone 9 diacetonealcohol Part B 0.02 Dabco T 1402 0.28 S405LF surfactant 70.27 ACPU-1(Hydroxyl-functional acrylic-polyurethane) 10.23% PM acetate (propyleneglycol methyl ether acetate)

Parts A and B were prepared as described in Example 1. Followinghomogenization, 19.20 parts by weight polyisocyanate were added at rateof 4% per minute at a mixing speed of 2000 rpm. The dispersion was mixedfor 45 minutes until smooth and homogenized. The formulation was appliedand dried as described in Example 1.

The ASTM D3363 standard test method for film hardness for thiscomposition was 8H. The ASTM D 523-89 standard test method for SpecularGloss values at Gloss 60° were 84.5-88.1, with high gloss (lacquer-likefinishes), a hard surface and soft feel.

Example 3

A waterborne top coat for industrial applications was prepared from anaqueous acrylic emulsion. This formulation incorporates the surfactant“POLYTERGENT” S-405-LF. The surfactant has a synergistic effect on thecoating in the wet state to minimize the formation of microfoam. Inaddition, increased gloss results from improved air release and lowfoam.

Parts by wt Component 62.29 “CARBOSET” CR-714 acrylic emulsion 0.00072“DEE FO 3000” (hydrocarbon defoamer) 0.398 “ARCOSOLV” (dipropyleneglycol tertiary butyl ether) 0.40 Glycol Ether EB 0.0019 “POLY-TERGENT”S-405-LF (surfactant) 0.00036 “SURFYNOL” DF-110D (nonionic polymerdefoamer) 0.0077 “TEGOGLIDE” 410 (polyether siloxane lubricant) 0.403“MICHEM” 39235 (Mar Additive)

A premier Caframo high intensity mixer at 1500 rpm was used to mix thedefoamer and the acrylic emulsion for about 20 minutes. The mixer speedwas reduced to 1000 rpm and the “ARCOSOLV” and the glycol ether EB wereadded and mixed for 10 minutes. The remainder of the ingredients wereadded to the mixture and blended. An aqueous ammonia solution (28%) wasadded to the emulsion to adjust the pH to about 7.5-7.8. The finalmixture was blended for 45 minutes until smooth and homogeneous.

The ASTM D3363 Standard test method for film hardness was determined tobe F-H, and the ASTM D 523-89 Standard test method for Specular Gloss atGloss 60° yielded a value of 68.4.

Example 4

A water based latex coating may be prepared as follows:

Parts by wt Component PART A: 106.15 water 1.5 hydroxyethyl cellulose(thickener) 25.9 propylene glycol 3.3 Tamol 731 (2,5- furandione polymerdispersant 0.95 Colloid 653, antifoamer 1.2 Troysan 731 preservative 125titanium dioxide PART B: 245.3 Joncryl 537 acrylic polymer 12.75 Texanol(ester alcohol solvent) 0.95 Colloid 653 (antifoam) 1.05 S-405-LF(surfactant) 0.5 NH₄OH (28%)

The first three ingredients from Part A were blended in a premierCaframo high intensity mixer at 1500 rpm, and then combined with theremaining Part A components. The resulting mixture was blended for 30minutes until smooth and homogenized. The components of Part B wereblended separately at 1500 rpm until thoroughly mixed, then added toPart A. The combined parts were blended for an additional 40 minutes.

The ASTM D3363 standard test method for film hardness by pencil test wasdetermined to be HB, and the ASTM D 523-89 standard test method forSpecular Gloss values at Gloss 60° was 20.9.

Although the invention has been shown and described with respect toillustrative embodiments thereof, it should be appreciated that theforegoing and various other changes, omissions and additions in the formand detail thereof may be made without departing from the spirit andscope of the invention as delineated in the claims. All patents andpatent applications mentioned are herein incorporated by reference intheir entirety.

We claim:
 1. A coated substrate, comprising: (1) a substrate; and (2) adry coating on said substrate, said dry coating consisting essentiallyof: (A) a resin selected from the group consisting of polyurethaneresin, acrylic resin, epoxy resin, polyester resin, alkyd resin, styreneacrylic copolymer resin, hydroxyl-functional acrylic-polyurethane resin,and combinations thereof; and (B) a surfactant; said surfactant having aformula selected from the group consisting of:H—(OCH₂CH₂)_(x)—(OCH₂CHCH₃)_(y)—(OCH₂CH₂)_(x)—OH  (i) where x is aninteger from 1 to 35, and y is an integer from 10 to 75; andH—(OCH(CH₃)CH₂)_(y)—(OCH₂CH₂)_(x)—(OCH₂CH(CH₃))_(y)—OH  (ii) where x isan integer from 5 to 20 and y is an integer from 15 to 25; wherein saidresin comprises from about 12 to about 85% by weight based upon thetotal weight of said dry coating, and said surfactant comprises 0.01 to3.0% by weight based upon the total weight of said dry coating; andwherein said dry coating has a soft feel, specular gloss of 75 orgreater as measured by the ASTM D523-89 method, and hardness of 8H orgreater as measured by the ASTM D3363 method.
 2. A process of coating asubstrate, comprising the steps of: applying a waterborne coatingcomposition to a substrate, said waterborne coating compositionconsisting essentially of a combination of (1) aqueous solvent, (2) aresin selected from the group consisting of polyurethane resin, acrylicresin, epoxy resin, polyester resin, alkyd resin, styrene acryliccopolymer resin, hydroxyl-functional acrylic-polyurethane resin, andcombinations thereof, and (3) a surfactant, said surfactant having theformula selected from the group consisting of:H—(OCH₂CH₂)_(x)—(OCH₂CHCH₃)_(y)—(OCH₂CH₂)_(x)—OH  (i) where x is aninteger from 1 to 35, and y is an integer from 10 to 75; andH—(OCH(CH₃)CH₂)_(y)—(OCH₂CH₂)_(x)—(OCH₂CH(CH₃))_(y)—OH  (ii) where x isan integer from 5 to 20 and y is an integer from 15 to 25; wherein saidaqueous solvent comprises about 20 to about 80% by weight based upon thetotal weight of said coating composition, said resin comprises fromabout 12 to about 85% by weight based upon the total weight of saidcoating composition, and said surfactant comprises 0.01 to 3.0% byweight based upon the total weight of said coating composition; andwherein said coating, when dried, has a soft feel, specular gloss of 75or greater as measured by the ASTM D523-89 method, and hardness of 8H orgreater as measured by the ASTM D3363 method.
 3. The process of claim 2,wherein said aqueous solvent is selected from the group consisting ofwater, water/N-methylpyrrolidone mixtures, water/propylene glycolmixtures, and combinations thereof.
 4. The process of claim 2, furthercomprising the step of drying said coating to form a dry coating on asubstrate.
 5. A coated substrate, comprising: (1) substrate; and (2) adry coating on said substrate, said dry coating consisting essentiallyof (A) a resin selected from the group consisting of polyurethane resin,acrylic resin, epoxy resin, polyester resin, alkyd resin, styreneacrylic copolymer resin, hydroxyl-functional acrylic-polyurethane resin,and combinations thereof; and (B) a surfactant having the formulaH—(OCH₂CH₂)_(x)—(OCH₂CHCH₃)_(y)—(OCH₂CH₂)_(x)—OH where x is an integerfrom 1 to 35, and y is an integer from 10 to 75; and wherein said drycoating has a soft feel, specular gloss of 75 or greater as measured bythe ASTM D523-89 method, and hardness of 8H or greater as measured bythe ASTM D3363 method.
 6. A coated substrate, comprising: (1) asubstrate; and (2) a dry coating on said substrate, said dry coatingconsisting essentially of (A) a resin selected from the group consistingof polyurethane resin, acrylic resin, epoxy resin, polyester resin,alkyd resin, styrene acrylic copolymer resin, hydroxyl-functionalacrylic-polyurethane resin, and combinations thereof; and (B) asurfactant having the formulaH—(OCH(CH₃)CH₂)_(y)—(OCH₂CH₂)_(x)—(OCH₂CH(CH₃))_(y)—OH where x is aninteger from 5 to 20, and y is an integer from 15 to 25; and whereinsaid dry coating has a soft feel, specular gloss of 75 or greater asmeasured by the ASTM D523-89 method, and hardness of 8H or greater asmeasured by the ASTM D3363 method.
 7. A process of coating a substrate,comprising the steps of: applying a waterborne coating composition to asubstrate, said waterborne coating composition consisting essentially ofa combination of (1) aqueous solvent selected from the group consistingof water, water/N-methylpyrrolidone mixtures, water/propylene glycolmixtures, and combinations thereof. (2) a resin selected from the groupconsisting of polyurethane resin, acrylic resin, epoxy resin, polyesterresin, alkyd resin, styrene acrylic copolymer resin, hydroxyl-functionalacrylic-polyurethane resin, and combinations thereof, and (3) asurfactant having the formula:H—(OCH₂CH₂)_(x)—(OCH₂CHCH₃)_(y)—(OCH₂CH₂)_(x)—OH where x is an integerfrom 1 to 35, and y is an integer from 10 to 75; wherein said aqueoussolvent comprises about 20 to about 80% by weight based upon the totalweight of said coating composition, said resin comprises from about 12to about 85% by weight based upon the total weight of said coatingcomposition, and said surfactant comprises 0.01 to 3.0% by weight basedupon the total weight of said coating composition; and wherein saidcoating, when dried, has a soft feel, specular gloss of 75 or greater asmeasured by the ASTM D523-89 method, and hardness of 8H or greater asmeasured by the ASTM D3363 method.
 8. The process of claim 7, furthercomprising the step of drying said coating to form a dry coating on asubstrate.
 9. A process of coating a substrate, comprising the steps of:applying a waterborne coating composition to a substrate, saidwaterborne coating composition consisting essentially of a combinationof (1) aqueous solvent selected from the group consisting of water,water/N-methylpyrrolidone mixtures, water/propylene glycol mixtures, andcombinations thereof. (2) a resin selected from the group consisting ofpolyurethane resin, acrylic resin, epoxy resin, polyester resin, alkydresin, styrene acrylic copolymer resin, hydroxyl-functionalacrylic-polyurethane resin, and combinations thereof, and (3) asurfactant having the formula:H—(OCH(CH₃)CH₂)_(y)—(OCH₂CH₂)_(x)—(OCH₂CH(CH₃)_(y)—OH where x is aninteger from 5 to 20 and y is an integer from 15 to 25; wherein saidaqueous solvent comprises about 20 to about 80% by weight based upon thetotal weight of said coating composition, said resin comprises fromabout 12 to about 85% by weight based upon the total weight of saidcoating composition, and said surfactant comprises 0.01 to 3.0% byweight based upon the total weight of said coating composition; andwherein said coating, when dried, has a soft feel, specular gloss of 75or greater as measured by the ASTM D523-89 method, and hardness of 8H orgreater as measured by the ASTM D3363 method.
 10. The process of claim9, further comprising the step of drying said coating to form a drycoating on a substrate.
 11. A coated substrate, comprising: (1) asubstrate; and (2) a dry coating on said substrate, said dry coatingconsisting essentially of (A) a resin selected from the group consistingof polyurethane resin, acrylic resin, epoxy resin, polyester resin,alkyd resin, styrene acrylic copolymer resin, hydroxyl-functionalacrylic-polyurethane resin, and combinations thereof; and (B) apoly(oxyethylene/oxypropylene)monohexyl ether surfactant; wherein saidresin comprises from about 12 to about 85% by weight based upon thetotal weight of said dry coating, and said surfactant comprises 0.01 to3.0% by weight based upon the total weight of said dry coating; andwherein said dry coating has a soft feel, specular gloss of 75 orgreater as measured by the ASTM D523-89 method, and hardness of 8H orgreater as measured by the ASTM D3363 method.
 12. A process of coating asubstrate, comprising the steps of: applying a waterborne coatingcomposition to a substrate, said waterborne coating compositionconsisting essentially of a combination of (1) aqueous solvent, (2) aresin selected from the group consisting of polyurethane resin, acrylicresin, epoxy resin, polyester resin, alkyd resin, styrene acryliccopolymer resin, hydroxyl-functional acrylic-polyurethane resin, andcombinations thereof, and (3) a poly(oxyethylene/oxypropylene)monohexylether surfactant; wherein said resin solvent comprises about 20 to about80% by weight based upon the total weight of said coating composition,said resin comprises from about 12 to about 85% by weight based upon thetotal weight of said coating composition, and said surfactant comprises0.01 to 3.0% by weight based upon the total weight of said coatingcomposition; and wherein said coating, when dried, has a soft feel,specular gloss of 75 or greater as measured by the ASTM D523-89 method,and hardness of 8H or greater as measured by the ASTM D3363 method. 13.The process of claim 12, wherein said aqueous solvent is selected fromthe group consisting of water, water/N-methylpyrrolidone mixtures,water/propylene glycol mixtures, and combinations thereof.
 14. Theprocess of claim 12, further comprising the step of drying said coatingto form a dry coating on a substrate.